Appendix A- Pallet Rack.pdf

APPENDIX A

FOR

PALLET RACK

AT

JOINT BASE CHARLESTON, SOUTH CAROLINA

FLIGHT LINE SUPPORT FACILITY

CSN: BCH205

DATE: 20 DECEMBER 2023

PREPARED BY:

Ashley Ambrose

ASHLEY AMBROSE

PROJECT ENGINEER

AFLCMC/EZPAE

Ronald Parsons

RONALD PARSONS

REVIEWER

AFLCMC/EZPAE

FA860424RB005 ATTACHMENT 2

THIS PAGE LEFT BLANK INTENTIONALLY

Joint Base Charleston – App A – Page i

Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

3.2.2. UPRIGHT FRAMES

3.2.2.1. COLUMNS

3.2.2.2. BEARING PLATES

3.2.2.3. DIAGONAL/HORIZONTAL BRACING

3.2.3. SHELF BEAMS

3.2.3.1. CONNECTORS

3.2.3.2. SHELF BEAM-TO-COLUMN SAFETY LOCK

3.2.4. LEVELING SHIMS

3.2.5. ANCHORING THE STRUCTURE

3.2.6. ASSEMBLY

3.2.7. DECKING

3.2.8. ROW SPACERS

3.2.9. FORKLIFT GUARD POSTS

3.2.10. WIRE PARTITIONS

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

4.2. TESTS

4.3. CERTIFICATIONS

Joint Base Charleston - App A - Page 1

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for pallet rack for the 628th Logistics Readiness Squadron (LRS) in the Flight Line Support Facility (FLSF) at Joint Base Charleston, South Carolina. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing BCH205-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.2. DEFINITIONS

Bay - A storage location in the pallet rack which measures from the front shelf beam to the back shelf beam in depth, and from the inside of the upright frame to the inside of the opposite upright frame in width.

Decking - A wire mesh surface spanning the area between two parallel shelf beams for the storage of loose or boxed items.

Pallet rack unit - A unit is an assembly of two upright frames and all shelf beams joining those two upright frames, and the wire mesh decking spanning the beams, or the rack supports.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD as well as RMI/ANSI MH16.1-2012 and RMI/ANSI

MH26.2-2007.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The pallet racks will be used to store palletized and small, medium, and large sized loads and loose items in such a manner to permit placement and removal of any individual load without disturbing any other load. Type A, C, and D shelving shall be free-standing and assembled as shown in AF Drawing BCH205-01.

Type B shall be assembled and utilized within the mobile aisle system. Wire decking shall be provided to facilitate storage of loose or boxed items. In addition to manual storage and retrieval by personnel the pallet rack shall permit storage and retrieval by existing 4k forklifts, and the rider-reach truck

Joint Base Charleston - App A - Page 2 specified in Appendix G. The pallet rack shall conform to the requirements of the Rack Manufacturers Institute (RMI) 2012 Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. CONFIGURATION REQUIREMENTS

The pallet rack units shall be located as shown on AF Drawing BCH205-01. The racks shall be capable of being assembled side-by-side, in a row, using common uprights to support the shelf beams. The pallet rack units shall be located and configured as shown on AF Drawing BCH205-01 and Table 1.

3.2.2. UPRIGHT FRAMES

The upright frames shall be of steel, all welded construction consisting of two columns, diagonal and horizontal braces, and floor bearing plates. Each upright frame shall be capable of supporting fully loaded bays without permanent deformation. The upright frames of like racks shall be interchangeable. Minimum upright frame capacities shall be as specified in Table 1. All upright frames shall have a minimum safety factor of 1.92 to 1.

Upright Frame Capacity (lbs.) by Rack Type

Shelving Configuration Shelf Beam Length

Upright Height

Number of

Levels

Load per Level

Load per Upright

Type A 108 168 4 6000 24000

Type B (Mobile Aisle) 84 96 5 1100 5500

Type C 108 96 4 1100 4400

Type D 108 84 4 1100 4400

Table 1. Upright Frame Capacities

3.2.2.1. COLUMNS

The columns shall be a continuous channel, box channel, rectangular, square, or other formation approved by the Contracting Officer’s Technical Representative (COTR). The minimum width of the column, facing the aisle, shall be 2-7/8 inches for Type A and 1-1/2 inches for types B, C, and D. Each column shall have openings to readily accommodate beam connectors, end-to-end, at corresponding heights through the height range of the column openings. For Types A, C, and D

Joint Base Charleston - App A - Page 3 pallet rack the openings at the bottom shall allow for the tops of shelf beams to be installed at six inches above the ground and shall continue upward to the top of the column by 2 inch increments. For Type B pallet rack the column openings and beam design shall allow the bottom of the beam to rest within 1-inchof the top of the mobile aisle frame. All openings of each column shall be identical to each other and identical to the openings of all other columns. The position of all corresponding openings of the columns shall not vary more than 3/32 inch as measured from the bottom of the bearing plates.

The arrangement of the openings and the fastening devices of the beams shall be such that the tops of the beams are flush, within 3/8 inch, with the top of the column.

3.2.2.2. BEARING PLATES

The bottom of each column shall have a load bearing plate securely attached. Each bearing plate shall be sufficiently sized to disperse the maximum load imposed by the column. Each bearing plate shall have a minimum of two punched holes to accept anchoring bolts in accordance with paragraph 3.2.5.

3.2.2.3. DIAGONAL/HORIZONTAL BRACING

The columns shall be braced by horizontal and diagonal braces.

Each end of all braces shall be securely welded to the columns.

The braces shall not protrude beyond the sides of the columns or obstruct the attachment of the shelf beams to the columns, at any height on the columns. The centerline of the bottom horizontal brace shall not be located more than 12 inches from the bottom of the upright frame, and the centerline of the top horizontal brace shall be located not farther than 12 inches from the top of the upright frame. Other diagonal and horizontal braces shall be uniformly spaced between the top and bottom horizontal braces.

3.2.3. SHELF BEAMS

Shelf beams shall be the box or step type. Any openings in the shelf beam construction shall face inward, they shall not face the aisle. The connector shall not be welded to the column.

Shelf beam-to-column connection shall be of the locking type.

Shelf beams for Type A rack shall have a minimum capacity of 6,000 pounds per bay. Shelf beams for Type B, C, and D rack shall have a minimum capacity of 1,100 pounds per bay. Loaded uniformily to the capacities specified above, there shall be no permanent deformations, and elastic deflections shall not exceed

0.56 percent of the unsupported span, measured with respect to

Joint Base Charleston - App A - Page 4 the two ends of the beam. Shelf beams shall be designed with a safety factor of 1.65 to 1. Every shelf beam shall be labeled with: Manufacturer, Part #, and Capacity. The labels shall be approximately 2” x 4” with the font size easy enough to read from a few feet away.

3.2.3.1. CONNECTORS

Each end of the shelf beams shall have a multiple prong slip-fit or slip-joint type shelf beam-to-column connector. Separate shelf beams and connectors are unacceptable. The connectors shall be adjustable, allowing the shelf beams to be moved with no more than the use of a soft hammer. The connector shall be capable of transferring all loads and external forces of the shelf beam to the column without failure of the connection, or damage to the column or connector. The prongs shall be of sufficient number, size, and strength to withstand repeated loading and unloading of the rack, and to continually sustain the rated shelf beam load. The prongs shall engage with the openings of the columns in such a manner to prevent lateral rotation of the beam, with each prong contributing to the support of the beam. The prongs shall engage with the openings of the columns to ensure a snug metal-to-metal fit between the horizontal and vertical load carrying members. The prongs shall be of the same design as the opening. The bottom load beam of widespan shelving Type B shall have the connector inverted such that the load beam can be configured closer to the mobile aisle carriage.

3.2.3.2. SHELF BEAM-TO-COLUMN SAFETY LOCK

Each shelf beam-to-column connection shall have a safety lock which shall lock the shelf beam to the column. The design and manner of construction of the device shall prevent accidental disengagement of the shelf beam-to-column connection during movement or shifting of the assembled rack unit due to impact to the upright frame or shelf beam from horizontal or vertical directions. The safety locking device shall be an integral, attached part of the shelf beam. The safety lock shall be employed without the use of tools, and no part thereof shall obstruct or restrict the loading or unloading of the racks.

3.2.4. LEVELING SHIMS

Leveling shims shall be provided with the rack units where necessary. The shims shall have holes corresponding to the holes in the bearing plate and shall anchor or lock with the

Joint Base Charleston - App A - Page 5 bearing plate when the rack is erected. Shims shall be equal in width and length to the bearing plate under which it is installed. Shims shall be of varying thickness so no more than five shims are installed at any point. Slotted shims shall be unacceptable.

3.2.5. ANCHORING THE STRUCTURE

The rack systems shall be anchored to resist all design shear and uplift forces. Pallet Rack shall be designed to be rigid and free standing. Pallet rack Types A, C, and D (lower level Mezzanine only) shall not be connected to any existing building structure except the floor. Each bearing plate shall be securely anchored to the floor with minimum one 1/2-inch diameter anchor bolt. The minimum embedment of the anchor shall be in accordance with 3.3.2.3 of the Cover PD. Pallet rack Type B shall be anchored to the mobile aisle frame with a bolt (1/4” diameter), lock washer, and nut. Pallet rack Type D located on the upper level of the Mezzanine shall be anchored to the mezzanine deck.

3.2.6. ASSEMBLY

The assembled pallet rack system shall be rigid, stable, and without deformation or skewing when each bay is loaded to the capacity of the design loads. The pallet rack system shall assemble so that the columns are perpendicular to the beams and parallel to each other. Shelf frames shall be straight and square. All horizontal members shall be level to within 1/8 inch per 10 feet measured over any distance in the rack system.

3.2.7. DECKING

Wire mesh decking shall be installed in all bays between all parallel shelf beams. No more than 2 pieces of wire mesh decking shall be used per shelving level. The decking shall be heavy duty welded steel wire with integral support channels capable of supporting a uniformly distributed load of 6,000 pounds per bay for the pallet racks Type A and 1,100 pounds per bay for pallet racks Type B, C, and D. The decking shall be designed with a safety factor of 1.65 to 1. The decking shall not exhibit permanent deformation and elastic deformations shall not exceed

0.56 percent of the unsupported span. Decking shall be R-Mark compliant. The decking shall be plated or galvanized to protect against corrosion. Decking shall be the appropriate type to interface with the type shelf beam being provided. The ends of the wire mesh decking shall bend over the shelf beam to provide a secure load supporting deck and keep the decking from accidentally disengaging from the shelf beams.

Joint Base Charleston - App A - Page 6

3.2.8. ROW SPACERS

Row spacers shall be capable of joining the backs of two upright frame sections together to form a double row arrangement. The row spacers shall provide a minimum 6-inch flue space when storage locations are back-to-back. Each end shall firmly and securely attach to the column and prevent unintentional disengagement. The row spacer shall be of sufficient size and strength to withstand all forces applied to the connected upright frames during normal loading and unloading operations without deformation or failure. The Contractor shall supply and install a minimum of 3 row spacers for each set of back-to-back frames. The top row spacer shall be installed within 24 inches of the top of the frame. The bottom row spacer shall be installed within 24 inches of the bottom of the frame.

3.2.9. FORKLIFT GUARD POSTS

Steel pipe forklift guard posts shall be provided as shown on AF Drawing BCH205-01. The guard post shall extend a minimum 3 feet above the floor and shall be installed in such a manner that they do not interfere with the normal usage of the pallet rack.

A cap shall be installed on the top of the guard post. The guard post shall not interfere with the normal movement of the forklifts and shall protect the corner upright frame from an accidental impact with a 4,000 pound capacity forklift. Each forklift guard post shall be anchored to the floor with a minimum of four anchor bolts in accordance with 3.3.2.3. of the Cover PD. The guard posts shall be painted safety yellow.

3.2.10. WIRE PARTITIONS

Wire partitions shall be provided to form two enclosed pilferable cages as shown on AF Drawing BCH205-01. The wire partitions shall be a free-standing type and attached to the floor. The wire partitions shall be constructed of a maximum 1-inch x 2-inch x 10-gauge wire mesh with corner posts. Horizontal stiffener channels and top capping channels shall be installed for rigidity. The color shall be powder coated gray. Wire Partition Type 1 cage shall be 10 feet high with and enclosed top. Wire Partition Type 1 cage shall have two swinging gates as shown on the AF Drawing BCH205-01. The gates shall be 8 feet high and provide a 6 foot wide opening. Wire Partition Type 2 cage shall be 10 feet high with and enclosed top. Wire Partition Type 2 shall have two sliding gates installed on the outside of the partitions as shown on the AF Drawing BCH205-01.

The gates shall be 8 feet high and provide a 12 foot wide

Joint Base Charleston - App A - Page 7 opening. Gates for both wire partition types shall have a padlock lug to enable the gates to be locked. Type 1 gates and Type 2 gates shall have different locks from each other. A lock and 3 keys shall be provided for each Type 1 and Type 2 gates.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTION

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TESTS

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Paragraph Description

1. 3.1. and 3.2.3.

Three pallet bays, picked at random, shall each be loaded to the capacity specified in this appendix to ensure the pallet beams are set in place. The loads shall then be removed. The distance from the top of each designated shelf beam to the top of the shelf beam above it shall be measured and recorded as M1. The loads shall then be put back into the designated pallet bays. The loads shall be left for a minimum of four continuous hours.

The distance from the designated shelf beams to the top of the next shelf beam shall be measured again and recorded as M2. The following formula shall be used to determine the deflection amount:

Deflection = [(M1 - M2) / shelf beam length ] * 100

If the deflection is greater than 0.56 or if permanent deformation exists when the loads are removed, the system shall fail.

Joint Base Charleston - App A - Page 8

2. 3.2.3.2. The shelf-to-column safety lock shall be tested at a minimum of ten random locations.

Personnel shall attempt to separate empty shelf beams from the column without disabling the shelf-to-beam safety lock. If a shelf separates from a column then the system fails the test.

3. 3.2.7. Three decking bays, picked at random, shall each be loaded to the capacity specified in this appendix to ensure the decking is set in place. The loads shall then be removed. The distance from the top of the deck to the top of the deck above it shall be measured and recorded as M1. The loads shall then be put back into the designated decking bays. The loads shall be left for a minimum of four continuous hours. The distance from the designated decking to the top of the decking above it shall be measured again and recorded as M2. The following formula shall be used to determine the deflection amount:

Deflection = [(M1 - M2) / shelf beam length ] * 100

If the deflection is greater than 0.56 or if permanent deformation exists when the loads are removed, the system shall fail.

4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.1. The pallet rack conforms to the requirements the Rack Manufacturers Institute (RMI) 2012 Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks.

2. 3.2.2. Upright frames shall have minimum safe load capacities as specified in Table 1. All uprights shall a safety factor of at least 1.92 to 1.

Joint Base Charleston - App A - Page 9

3. 3.2.2.2. The bearing plates are of sufficient size to disperse the maximum load imposed on the column.

4. 3.2.3. All shelf beams are designed for, constructed to, and capable of sustaining the minimum safe load with a safety factor of at least 1.65 to 1

5. 3.2.7. Certify the wire deck is R-Mark compliant.

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

Joint Base Charleston – Pallet Rack TPQ - Page 1 of 5

PALLET RACK

Solicitation Number: FA8640- -R- Project Title: Storage Aids System Base: Joint Base Charleston CSN: BCH205 Appendix A – Pallet Rack, 20 December 2023

This questionnaire shall be completed by the Offeror. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment.

Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the Purchase Description Appendix as detailed below.

Pallet Rack Manufacturer: ______________________________________

No. Paragraph Characteristics

1. 3.2.1. Pallet rack unit dimensions:

Type A:

Width: inches Depth: inches Height: inches

Number of shelf beam pairs between uprights: ____

Type B:

Width: inches Depth: inches

Type C:

Depth: inches

Type D:

Depth: inches

Solicitation Number: FA8604- -R-

Joint Base Charleston – Pallet Rack TPQ - Page 2 of 5

2. 3.2.2. Upright frame part number: _____________________

Minimum capacity of Type “A” upright frames:

________ pounds

Upright frame part number: _____________________ Minimum capacity of Type “B” upright frames:

Minimum capacity of Type “C” upright frames:

Minimum capacity of Type “D” upright frames:

Safety factor of: ________________________ to 1

3. 3.2.2.1. Type “A”:

Width of column facing the aisle: _______ inches Type “B”, “C”, and “D”:

Width of column facing the aisle: _______ inches Vertical center-center spacing of column openings for shelf beam adjustment: ____ inches

4. 3.2.2.2. Number of punched holes per bearing plate: _____

Joint Base Charleston – Pallet Rack TPQ - Page 3 of 5

5. 3.2.3. Type “A” Shelf beam part number: ________________________ Type of shelf beam: ____________________________ Bay width provided by shelf beam: _______ inches Minimum capacity per bay: _______________ pounds

Type “B” Shelf beam part number: ________________________ Type of shelf beam: ____________________________ Bay width provided by shelf beam: _______ inches Minimum capacity per bay: _______________ pounds

Type “C” Shelf beam part number: ________________________ Type of shelf beam: ____________________________ Bay width provided by shelf beam: _______ inches Minimum capacity per bay: _______________ pounds

Type “D” Shelf beam part number: ________________________ Type of shelf beam: ____________________________ Bay width provided by shelf beam: _______ inches Minimum capacity per bay: _______________ pounds

6. 3.2.3. Safety factor of: _________________________ to 1

7. 3.2.3. Will shelf deflection meet the requirements as specified?

YES NO

8. 3.2.3.2. Will shelf beam-to-column safety locks be provided as specified?

9. 3.2.4. Will leveling shims be provided as specified?

Joint Base Charleston – Pallet Rack TPQ - Page 4 of 5

10. 3.2.5. Types “A”, “C”, and “D”:

Diameter of anchors to be provided: ______ inches

Length of anchors to be provided: ________ inches

Number of anchors per bearing plate: ____________

Type “B”:

Diameter of anchors to be provided: ______ inches

11. 3.2.7 Will wire decking be provided as specified:

YES NO

Capacity of decking:

Type “A”: ___________ pounds Type “B”: ___________ pounds Type “C”: ___________ pounds Type “D”: ___________ pounds

12. 3.2.9. Impact forklift guard post can withstand: ___lbs

Number of anchor bolts for each post: __________

Joint Base Charleston – Pallet Rack TPQ - Page 5 of 5

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken?

Number of pages attached: ____________________________________